The reverse-head Yamaha YZs and WRs have a fiddly system to remove the petrol tank thanks to the fuel injection system. There is the fuel pump wiring plug, then a plastic retaining clip on the fuel hose plug and, finally, the “quick-release” fuel plug itself, all to be removed while trying to hold the fuel tank with your other arm.

Instead of trying to remove the plugs and clip, turn the tank around backwards and position it on the subframe so you can still get to the rocker cover and work on the engine without the tank being in the way.

Step 1 Undo the seat bolts and unclip the front, removable section of the seat. Take the seat off and set it aside.

Step 2 Unclip the airbox cover, remove it and set it aside out of the way.

Step 3 Remove the radiator shrouds by removing all the 5mm bolts holding them in place. Two of these bolts are longer as they also hold the front of the tank in place.

Step 4 Once the shrouds have been removed there will be one last bolt in the back of the tank that needs to be removed.

Step 5 Lift the tank up and careful turn it backwards without crimping or twisting the fuel line. Place it on the subframe out of the way. To keep it in place, hold it  down with an ocky strap or tiedown.

Step 6 Once you have finished checking your valve clearances or whatever else you are doing under the tank, refit the fuel cell, being careful to turn the tank forwards without kinking the fuel line.

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TOOLS 8MM T-BAR, 10MM T-BAR, OCKY STRAP

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DO’s

  1. Do rotate the tank instead of removing it completely – turn the fuel tank backwards and rest it on the subframe so you can still access the rocker cover without disconnecting the fiddly fuel system.
  2. Do secure the tank properly – once turned around, use an ocky strap or tiedown to hold it in place and prevent movement while you work.
  3. Do handle fuel lines carefully – lift and rotate the tank slowly, keeping an eye on the hose to avoid kinking, twisting, or stretching the quick-release connection.

DON’Ts

  1. Don’t disconnect unnecessary plugs or clips – avoid removing the fuel pump wiring plug, hose clip, or quick-release fitting unless absolutely required.
  2. Don’t force the tank – never yank or twist the tank against resistance; the plastic fuel fittings are fragile and expensive to replace.
  3. Don’t refit hastily – when reinstalling, make sure the tank is aligned correctly and fuel lines aren’t pinched before tightening bolts and clips.

Technical Editor Mat Boyd